Production ramp-up in European automotive production systems: a performance analysis

Abstract

Many new model launches in Europe do not meet the quality, cost and production targets set by automotive companies during production ramp-up. Although increasing car complexity could be a key factor in explaining this issue, it is not sufficient to explain why production sites are not able to meet these important targets. This article analyses whether the production system used in European car manufacturing plants are suitable for achieving performance goals during the production ramp-up phase. First, the differences between serial production and the production ramp-up phase are analyzed through the conceptual framework of the European Production System in the automotive industry. Second, a case study using real data from a European automotive plant is presented, and the evidence calls into question the appropriateness of maintaining the same production system during the ramp-up phase. The study concludes that there is a need to make the production system in Europe more flexible during the ramp-up phase. In particular, changes should be more oriented towards fostering organizational improvement capability in order to reduce the stops that occur in the production line, avoid using pull systems as a constraint or limitation, and help to build a new culture of stopping to fix problems.

Keywords:

• Ramp-up
• start-up
• automotive industry
• production system
• European case study

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Notes on contributors

Elisabeth Viles

Elisabeth Viles holds a PhD in Applied Physics from the University of Navarra and a BA in Mathematics Science from the University of Zaragoza. She is a certificated Six Sigma Black Belt. Currently, she is Professor of Statistics and Probability and Industrial Statistics at TECNUN. She also is head of the Industrial Management Department and coordinator of the Industrial Management Degree at TECNUN. She has been actively conducting and publishing research on the application of statistical thinking tools and other continuous improvement methodologies in industry for more than ten years. She heads the Sustainable Improvement Research Group at TECNUN and she also belongs to the Statistical Design and Data Analytics Group at the University of Navarra. She teaches different postgraduate courses related to quality management, continuous improvement management, Six Sigma implementation and Black Belt training.

Ramón Bultó

Ramón Bultó holds a degree in Industrial Engineering (1991) and a Master’s degree in Research in Applied Engineering from TECNUN, the School of Engineering at the University of Navarra, as well as an MBA (2011) from IESE. His main research area is ramp-up management. He works in the private sector as a product manager in the automotive industry.

Ricardo Mateo

Ricardo Mateo holds a degree in Industrial Engineering and a PhD in Management and Economics from the University of Navarra. He also holds an MBA from IESE. His research mainly focuses on continuous improvement in industrial and health organizations. He is professor of Strategic Management at the School of Economics and Business Administration of the University of Navarra. With regard to executive education and professional training, he has worked with the most renowned multinational companies and hospitals in the region.

Daniel Jurburg

Daniel Jurburg holds an Industrial Engineering degree from Universidad de Montevideo (Uruguay), a Master degree in Research in Applied Engineering from Universidad de Navarra (Spain), and a PhD degree from TECNUN – Universidad de Navarra (Applied Engineering Programme). He is currently responsible for the continuous improvement research group at CINOI (the Industrial Management Innovation Centre from the Engineering Faculty at UM). Daniel is active member within the National Research System (SNI – ANII), and is part of the Honorary Advisory Board of the National Institute for Quality (INACAL). He has participated in many research projects, and has published several articles in international peer reviewed journals about supply chain management and continuous improvement topics.